Hangable package structure

ABSTRACT

A hangable package structure for use with small, heavy products that are sold in blister card packages is disclosed. The package can be suspended from a peg or displayed on a shelf without using a tray or other holder. The package prevents the occurrence of a problem known as “hanger hole tear-through” of the blister card and provides for partial portability of the purchased product.

BACKGROUND OF THE INVENTION

This invention is directed to hangable packages typically employed in aself-serve retail environment where consumers can select individualpackages from a shelf or rack. In particular, this invention is directedto packages that include a card which is hung from a peg that passesthrough an opening in the top of the card.

Package structures used to display articles for sale come in a widearray of designs. The ideal package is inexpensive to manufacture usingwell known manufacturing equipment and has several features that areimportant to the consumer and/or the retail store's personnel. Forexample, in order to maximize the merchant's flexibility for displayinga package at various locations throughout the store, the package shouldbe both peggable as well as able to stand without needing a holder ortray. Peggable packages are packages that can be suspended from agenerally horizontal rod that passes through an opening in the package.Another desirable feature is partial portability which means that aportion of the package's contents, including a portion of the packagingitself, can be removed from the initial package structure withoutdestroying the integrity and usefulness of the initial package. Anotherdesirable feature is that the consumer can easily and reliably verifythe package's contents before making the purchase. A feature that isimportant to store owners is that the package enables a sufficientlyhigh level of product density which means that the amount of wastedspace within a single package or between packages on a display rack isminimized. To counteract the problem of some consumers stealing aportion of the product from a package and then returning the partiallydepleted package to the store shelf, the package should be sufficientlyrobust to minimize pilferage while also providing easy access to theproduct by consumers who legally purchase the package. Finally, theideal package will provide adequate space on the package's exteriorsurface for advertising, logo placement, instructions regarding theproduct, etc.

One of the most popular package structures is generally referred to as a“blister card.” The basic components of the blister card are arectangularly shaped card member having a thickness of approximately 6.6mm and a thermally formed cup shaped container made of a transparentplastic material that surrounds the merchandise to be displayed andsold. The container is secured to the card member which is hung from apeg that is attached on one end to a vertical surface such as a displaystand. The card is hung by inserting one end of the peg through anopening in the card that is located near an edge of the card.Conventional blister cards perform satisfactorily when the merchandisein the container is not too heavy. For example, products such as pencilsor small quantities of paper clips are well suited for sale in blistercards.

Unfortunately, the use of a blister card package structure to displayand sell heavy products can cause problems for the retail store owners,customers, and manufacturers of the goods for sale. Examples of heavyproducts that are conventionally sold in blister card package structuresinclude cylindrically shaped standard alkaline batteries that are usedby consumers to power digital cameras, flashlights, toys, etc. Whenseveral batteries, such as twelve or more AA size batteries or at leastsix C size or D size batteries, are housed in a single blister cardpackage, the weight can exceed three hundred grams. When the merchandiseto be sold is too heavy, some of the blister card packages suffer from aproblem known as “hanger hold tear-through.” A blister card with a tornhanger hole is shown in FIG. 1. This problem occurs when section 21,located between the hanger hole opening 25 in the card member and theclosest edge 27 of card member 23, tears away thereby allowing the cardto fall from the peg. Because the card has been torn, store personnelcannot return the blister card to the peg so that the merchandise can bedisplayed and sold.

Another cause of the hanger hole tear-through problem is rough handlingof the blister card package by consumers. When a blister card package isremoved from a peg, the consumer may inadvertently pull down on thepackage causing the peg to tear the card above the hangar hole. If theconsumer should then decide not to purchase that package, it cannot berehung on the peg because the card was accidentally torn.

In addition to occurring within a retail store, the hanger hole tearthrough problem can occur during shipment of the blister carded productfrom the manufacturer of the merchandise to the store. This problem isparticularly noticeable when a merchandiser containing blister cards isshipped preloaded. In this situation, a merchandiser containing pegs, onwhich blister card packages have been hung, is shipped from themanufacturer to the retailer. The retailer can then unpack and use thefully loaded merchandiser without needing to hang peggable packages onthe pegs. During shipment, which typically takes place via truck, thepackages may be frequently jostled or vibrated on the peg for hours ordays. Because the card is suspended from the peg, the peg works toweaken the card so that the card tears between the hanger hold and theedge of the card thereby allowing the package to fall. Despite knowingthat the merchandise contained within the package is not damaged, mostcustomers elect not to purchase a package with a torn hanger hole. Thetorn packages are then returned to the manufacturer where the productmust be repackaged before it can be sold. This step needlessly increasesthe manufacturer's cost.

Another problem with using blister card package structures is that thepackage cannot stand by itself in a vertical position. As shown in FIG.2, this problem is caused by a lower edge 29 of the card member 23projecting beyond the cavity 31 that contains the merchandise so thatthe package tilts when allowed to stand by itself on a horizontalsurface. This problem is caused by the extension of the cavity's lowerflange 33 that must be secured to the card member in order to seal themerchandise into the cavity. Manufacturers of the product contained inthe blister card, as well as retail store personnel, would benefit froma package that is capable of hanging from a peg or standing in avertical position without the support of a tray or other holder.

Previous attempts to solve the hanger hole tear-through problem haveincluded the following concepts. First, as disclosed in U.S. PatentApplication Publication No. 2002/0170218A1, a piece of tape may beapplied to the top of the card member between the hanger hole and theedge of the card. The tape reinforces the card above the hanger hole,thereby strengthening the card so that the tear-through problem issignificantly reduced or eliminated. Second, as disclosed in U.S. DesignPat. No. 427,523, the top of the card may be folded over to create adouble thickness of card between the hanger hole and the edge of thecard. However, neither the application of tape to the card nor thefolding over at the top of the card resolve both the hanger holdtear-through problem and enable the package to stand by itself on ahorizontal surface.

BRIEF SUMMARY OF THE INVENTION

The present invention solves problems associated with the use ofconventional blister card package structures that may be displayed byhanging the package or by standing it on a horizontal surface. Thepresent invention is capable of holding small heavy items without thecard tearing above the hanger hole and the same package may be used in afree standing vertical orientation.

The present invention is a hangable package structure having a partiallyenclosed interior region that houses at least one compartment. Thestructure includes a folded strip shaped base member having a planarsurface, a first end that defines a first opening through the basemember, and a second end that defines a second opening through the basemember. The base member's midsection is located between and separatesthe first end from the second end. The first opening in the base memberaligns with the second opening in the base member to provide anunobstructed path through a partially enclosed interior region which isdefined on three sides by the first end, the second end, and themidsection. A first compartment is secured to the planar surface of thebase member's first end and is located within the partially enclosedinterior region.

In another embodiment, the present invention is a process formanufacturing a package structure. The process includes the followingsteps. Providing a strip shaped base member having a planar surface, afirst end that defines a first opening through the base member, a secondend that defines a second opening through the base member, and amidsection that is located between and separates the first end from thesecond end. The first end abuts the midsection at a first axis and thesecond end abuts the midsection at a second axis. Providing a firstcompartment having an opening. Securing the planar surface of the basemember's first end over the opening in the compartment. Folding the basemember to align the first opening with the second opening to provide anunobstructed path through the partially enclosed interior region whichis defined on three sides by the first end, the second end, and themidsection. The compartment is housed within the partially enclosedregion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a conventional peggable package with atorn hanger hole;

FIG. 2 is a side view of a conventional peggable package resting on ahorizontal surface;

FIG. 3 is a perspective view of a base member that is useful in apackage structure of this invention;

FIG. 4 is a perspective view of a first compartment suitable for use ina package structure of this invention;

FIG. 5 is a side view of the first compartment shown in FIG. 4;

FIG. 6 is a perspective view of a second compartment suitable for use ina package structure of this invention;

FIG. 7 is a side view of the second compartment shown in FIG. 6;

FIG. 8A is a side view of the first compartment shown in FIG. 5 withitems loaded into the compartment's cavity;

FIG. 8B is a side view of the second compartment shown in FIG. 7 witharticles being loaded into the compartment's cavities;

FIG. 9 shows the base member being sealed over the openings in thecavities of the first and second compartments;

FIG. 10 is a perspective view of a partially folded package structure ofthis invention;

FIG. 11 is a side view of a completely folded package structure of thisinvention;

FIG. 12 is a perspective view of a package structure of this inventionhung on a peg;

FIG. 13 is a cross sectional view of a folded package structure of thisinvention; and

FIG. 14 is a side view of a folded package structure of this invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings and more particularly to FIG. 3, there isshown a base member 20. The base member has a first end 22, a second end24, and a midsection 26. The first end defines first opening 28 throughbase member 20. The second end defines second opening 30 through basemember 20. First opening 28 and second opening 30 are sometimes referredto as hanger holes. First end 22 abuts midsection 26 at first axis 32.Second end 24 abuts midsection 26 at second axis 34. First axis 32 andsecond axis 34 are parallel to one another and function as flexibleconnections. One or both of the axes may be perforated to facilitateseparating the base member into two or more sections by tearing the basemember at the perforations. Base member 20 is a rectangularly shapedstrip of paperboard material. The base member includes a planar surface36.

Indicia, such as logos and advertising, may be printed on the side ofthe base member opposite the planar surface. Abutting one edge of firstend 22 is an optional first locking tab 38. Abutting one edge of secondend 24 is an optional second locking tab 40. Base member 20 has alongitudinal axis 42.

FIG. 4 shows one embodiment of first compartment 50, which includes afirst cavity 52 and two anti-bowing ribs 54 and 56. Formed along twosides of first cavity 52 are protrusions 58 and 60. Flange area 62encircles the perimeter of first compartment 50. FIG. 5 is a side viewof first compartment 50.

FIG. 6 is a perspective view of a second compartment 70 having a firstcavity 72 and a second cavity 74. Second compartment 70 includesanti-bowing ribs 76 and 78. Locking protrusions 80 and 82 are located oncavities 72 and 74, respectively. Flange area 84 defines the perimeterof second compartment 70. FIG. 7 is a side view of second compartment70.

As shown in FIGS. 4 and 6, first compartment 50 and second compartment70 may be formed as separate components which are individually attachedto the base member. However, if desired, both compartments could beformed from a single strip of material so that a portion of the materialbridges the midsection of the base member. If both compartments areformed from a single strip, then openings must be created in the stripto align with openings 28 and 30 in base member 20.

FIG. 8A is a side view of first compartment 50 with four articles 90stored in first cavity 52. FIG. 8B is a side view of a secondcompartment 70 with a plurality of articles 90 loaded into first cavity72. Four additional articles are flowing into cavity 74.

FIG. 9 shows base member 20 as it is secured over the cavities in firstcompartment 50 and second compartment 70. The distance between the firstcompartment and the second compartment is approximately equal to thewidth of the base member's midsection 26. The base member may be sealedto the compartments using conventional technologies such as an adhesive,tape, the application of heat, or various welding techniques such as theuse of ultrasonic energy.

FIG. 10 shows a partially folded package, wherein second end 24 has beenrotated about axis 34. To completely fold the package as shown in FIG.11, first end 22 (in FIG. 10) is rotated about axis 32 so that ends 22and 24 are parallel with one another. The folding process causes cavity52 to be inserted between cavities 72 and 74. Protrusions 58 and 60 oncavity 52 are forced past protrusions 80 and 82 on cavities 72 and 74.The protrusions prevent the cavities from freely disengaging from oneanother, thereby requiring the consumer to exert some force on the freeends of the compartments in order to force them apart so that thearticles stored therein can be accessed.

In addition to the protrusions previously described, other designs canbe used to create a means for securing the cavities, and thus thecompartments and ends of the base, into a single unitary package. In analternate embodiment, protrusions 58 and 60 on cavity 52 could be madeto engage recesses (not shown) instead of protrusions in cavities 72 and74. Alternatively, one or more protrusions on the base of a cavity couldbe made to engage a recess in the surface of the opposing compartment.Yet another alternative is to use protrusions and recesses on the ribsand the cavities to create a means for interlocking the cavities formedin one compartment to the ribs formed in the opposing compartment.

The present invention may also comprise a base member having more thantwo ends. For example, a base member in the shape of a cross, ratherthan a strip, would have four ends that could be folded upon one anotherto create a rectangularly shaped package.

Anti-bowing ribs 54, 56, 76 and 78, shown in FIG. 10, are designed toprevent outward bowing of the package's sides when folded packages, suchas the one shown in FIG. 11, are stacked on top of each other in avertical orientation. For example, during shipment of the foldedpackages from the manufacturer to the retailer, the packages may bestacked on top of each other in a master shipping container. If thepackages are stacked so that midsection 26 of the package at the bottomof the container abuts locking tab 40 of an adjoining package, then thepackage at the bottom of the stack must be able to support the weight oftwo packages without bowing and suffering a structural failure. Theanti-bowing ribs are intended to provide sufficient structural supportto prevent bowing of the package that would occur if the anti-bowingribs were not present. To be most effective, the anti-bowing ribs mustcross the longitudinal midpoints of the first end 22 and second end 24of base member 20. The ribs may be formed as an integral part of firstcompartment 50 or second compartment 70. Alternatively, the ribs couldbe formed as separate elongated components that are then secured to acompartment.

The distance between two ribs, such as ribs 76 and 78 in FIG. 6, shouldbe equal to or slightly greater than the width of base 53 of cavity 52.Similarly, the distance between ribs 54 and 56 in FIG. 4 should be equalto or slightly greater than the width of base 73 of cavity 72 and thewidth of base 75 or cavity 74. Preferably, the distance between two ribsformed on the same compartment creates a slight interference fit withthe base of the opposing compartment's cavity thereby enabling the ribsto prevent undesirable side-to-side movement of the cavities when thepackage is folded as in FIG. 11.

As shown in FIG. 11, the base member's locking tabs 38 and 40 can besecured to one another to create a fourth side which functions as anoptional means for locking the folded base strip and compartments into aunitary package. In one embodiment, the tabs may be glued to oneanother. In another embodiment, the tabs may be configured so that aportion of tab 38 fits through a slot in tab 40 thereby enabling thefirst and second ends of the base member to be releasably secured to oneanother.

Shown in FIG. 12 is a merchandiser having a folded package structurehung from a support means. The folded package structure is hung from anelongated horizontal support member 101, such as a peg, that is securedon its proximate end 106 to a vertical surface 108 such as a wall. Thedistal end 110 of support member 101 is inserted through the firstopening 28 in first end 22, the unobstructed path 102 in the partiallyenclosed region 104 and then through the second opening 30 in second end24. The package structure 100 shown in FIG. 12 is a preferred embodimentof the claimed invention. Package 100 can be used to display small heavyobjects, such as twelve AA size alkaline batteries, by hanging thepackage from a peg or by placing the package on a horizontal surface inan upright position. Base member 20 includes four panels, previouslyidentified as first end 22, midsection 26, second end 24, and lockingtabs 38 and 40, that cooperate to define a partially enclosed region 104that houses and protects the merchandise contained in cavities 52, 72and 74. Because the package is not enclosed on two sides, a consumer canvisually inspect the merchandise before purchasing the package. However,the four panels that define the exterior surface of the package providea substantial barrier to pilferage of some or all of the merchandisewhen the package is on display in the store. Midsection 26 of basemember 20 reinforces the area above hanger hole openings 28 and 30thereby preventing hanger hole tear through. As described earlier, thebase member's axes may be perforated between cavities 52, 72 and 74,thereby allowing individual cavities to be removed from the packagewithout destroying the remaining portion of the package and the unusedbatteries are kept within the original package until they are needed.Alternatively, perforations 92, as shown in FIGS. 4 and 6, may bepositioned around each cavity to facilitate removal of the cavity fromthe compartment after the package has been purchased and unfolded by theconsumer. Perforations 92 need to extend through both base member 20 andthe compartment in which the cavity is formed. Protrusions 58 and 60 oncavities 52, 72 and 74 provide a means for releasably securing thecavities to one another thereby enabling the package to resist rackingduring shipment and/or storage by the consumer.

A cross sectional view of another embodiment of a package of thisinvention is shown in FIG. 13 wherein a single compartment 94 is securedto base member 20. A side view of yet another embodiment of a package ofthis invention is shown in FIG. 14 wherein a single strip 86 of materialis used to form both compartments, 96 and 98, as well as a middleportion 88 that abuts midsection 26 of strip 20.

The above description is considered that of the preferred embodimentsonly. Modifications of the invention will occur to those skilled in theart and to those who make or use the invention. Therefore, it isunderstood that the embodiments shown in the drawings and describedabove are merely for illustrative purposes and are not intended to limitthe scope of the invention which is defined by the following claims asinterpreted according to the principles of patent law.

1. A peggable package structure having a partially enclosed interiorregion housing at least one compartment, said structure comprising: a) afolded strip shaped base member having a planar surface, a first endthat defines a first opening through said base member, a second end thatdefines a second opening through said base member and a midsectionlocated between the first and second ends, wherein said first opening insaid base member aligns with said second opening in said base member toprovide an unobstructed path through a partially enclosed interiorregion defined on three sides by said first end, said second end andsaid midsection; and b) a first compartment secured to the first end ofsaid base member's planar surface and housed within the partiallyenclosed interior region.
 2. The package structure of claim 1, furtherincluding an anti-bowing reinforcing member secured to said basemember's planar surface.
 3. The package structure of claim 2, whereinsaid reinforcing member is secured to the planar surface of said basemember's first end.
 4. The package structure of claim 3, wherein saidbase member comprises a longitudinal axis and said reinforcing membercomprises an elongated rib oriented parallel to the longitudinal axis.5. The package structure of claim 4, wherein said reinforcing memberextends across the longitudinal midpoint of said first end.
 6. Thepackage structure of claim 1, further comprises a second compartmentsecured to said second end's planar surface.
 7. The package structure ofclaim 6, further comprises a releasable interlocking means forpreventing movement of said compartments within said partially enclosedregion.
 8. The package structure of claim 7, wherein said interlockingmeans comprises a protrusion on said first compartment and a recess onsaid second compartment, wherein said protrusion engages said recess,thereby releasably securing one compartment to the other compartment. 9.The package structure of claim 1, wherein said first end abuts saidmidsection at a first flexible connection and said second end abuts saidmidsection at a second flexible connection.
 10. The package structure ofclaim 9, wherein said base member comprises a longitudinal axis and saidflexible connections are perpendicular to the longitudinal axis.
 11. Thepackage structure of claim 9, wherein said first opening is proximatesaid first flexible connection and said second opening is proximate saidsecond flexible connection.
 12. The package structure of claim 1, saidbase member comprises a locking means in contact with said first end andsaid second end.
 13. The package structure of claim 12, wherein saidlocking means defines a fourth side of said partially enclosed interiorregion.
 14. A process for manufacturing a package structure, comprisingthe steps of: a) providing a strip shaped base member having a planarsurface, a first end that defines a first opening through said basemember, a second end that defines a second opening through said basemember and a midsection located between and separating the first endfrom the second end; b) providing a first compartment having an opening;c) securing the planar surface of said base member's first end over theopening in said compartment; and d) folding said base member to alignsaid first opening with said second opening to provide an unobstructedpath through the partially enclosed interior region defined on threesides by said first end, said second end and said midsection, whereinsaid region houses said first compartment.
 15. The process of claim 14,wherein said first end abuts said midsection at a first axis and saidsecond end abuts said midsection at a second axis, said first axis andsaid second axis located parallel to each other.
 16. The process ofclaim 14, wherein said base member comprises a longitudinal axis andsaid base member's two separate axes are perpendicular to thelongitudinal axis and parallel to each other.
 17. The process of claim14, wherein step b further includes providing a second compartmenthaving an opening and step c further includes securing the planarsurface of said base member's second end over the opening in said secondcompartment.
 18. The process of claim 17, wherein said first compartmentcomprises a protrusion and said second compartment comprises a recess,said process further includes the step of engaging said protrusion withsaid recess to removably secure the compartments to one another.
 19. Theprocess of claim 14, wherein said base member comprises a locking meansin contact with an end of said base and said process further includesthe step of engaging said locking means to releasably secure said firstend to said second end.
 20. The process of claim 19, wherein saidlocking means provides a fourth side to said partially enclosed region.21. The process of claim 17, wherein said first compartment comprises afirst protrusion and said second compartment comprises a secondprotrusion, said process further includes the step of engaging saidfirst protrusion with said second protrusion to removably secure thecompartments to one another.
 22. A merchandiser, comprising: a hangablepackage structure and a support means from which the package structureis removably suspended, wherein said package structure comprises afolded, strip shaped base member having a planar surface, a first endthat defines a first opening through said base member, a second end thatdefines a second opening through said base member, and a midsectionlocated between and separating the first end from the second end,wherein the first opening in said base member aligns with said secondopening in said base member to provide an unobstructed path through apartially enclosed interior region defined on three sides by said firstend, said second end and said midsection, said package structure furthercomprises a first compartment secured to the planar surface of said basemember's first end and located within said partially enclosed interiorregion; and said support means comprises an elongated membersimultaneously extending through said package structure's first opening,unobstructed path and second opening, said support means contacting andsupporting said first end and said second end thereby suspending saidpackage from said support means.
 23. The merchandiser of claim 22,wherein said support means comprises a first proximal end secured to asupporting structure and a second distal end that extends through thepackage structure.